Mobile rebar supply system for providing unlimited lengths

ABSTRACT

A vehicle supported system having a support frame, a support surface, a number of a coil handlers and a coil leveler, all supported upon the support surface. The coil handlers are configured to rotatably support a coil of reinforcing bar material in a manner which allows the reinforcing bar materials to be unwound and fed from the coil. The coil leveler may be configured to receive the reinforcing bar materials and to perform a straightening operation which will provide a straightened rebar material at an output of the mobile outfeed device. The system may also include a mobile cutter positioned adjacent outfeed device to cut reinforcing bar materials to a desired length when that length has been provided through the output.

BACKGROUND

Reinforcing bar (hereinafter referred to as rebar or re-bar) used tostrengthen concrete structures is often delivered to jobsites inpredetermined lengths. For example, re-bar is typically delivered to ajobsite in 20-foot lengths, since this is a common length for handling,as it can be easily carried by flatbed trailers and can beunloaded/handled using forklifts or front-end loaders. Using materialdelivered at these lengths, contractors can then form internal re-barstructures that will be situated within poured concrete structures ofmany types (e.g., buildings, bridges, roadways, etc.). Delivering re-barin these lengths however creates challenges when the structures beingfabricated are longer, thus requiring some creativity to provide longerruns or spans of re-bar. In practice, these longer runs are typicallyachieved by tying together multiple segments. While effective, this istime consuming and labor intensive. In addition, the industry standardcalls for a 2-foot overlap when re-bar is tied together, thus adding tothe complexity of these “pieced together” structures and the timerequired to create them.

SUMMARY

A mobile re-bar delivery system can provide a supply of re-bar materialsof practically unlimited lengths to a jobsite efficiently andeffectively, thereby avoiding the need for excess labor and complexitywhen producing concrete structures reinforced with re-bar. To accomplishthis, a vehicle having a support frame and a support surface are provideto support a coil handler which will rotatably support a coil ofreinforcing bar material in a manner which allows the reinforcing barmaterials to be unwound and fed from the coil. An outfeed device ispositioned adjacent to the coil handler and is configured to performstraightening operations, thereby providing a straightened re-barmaterial at an output of the outfeed device. A cutter is also positionedadjacent outfeed device to cut reinforcing bar materials to a desiredlength when that length has been provided through the output.

In some aspects, the mobile system is configured so the outfeed deviceand the mobile cutter are rotatably supported upon the vehicle supportsurface, thus allowing for the selective alignment of these components.

In further aspects, the mobile re-bar supply system further includes abending device positioned adjacent the cutter which is configured tobend the desired length of reinforcing bar materials into apredetermined configuration.

From other perspective, the mobile re-bar delivery system is configuredso that the outfeed device, the mobile cutter and the bending device arerotatably supported upon a turntable, which is positioned upon thevehicle support surface. The mobile re-bar delivery system may beconfigured so that the turntable supports at least two spools of re-barmaterial.

In an alternative embodiment, the mobile rebar delivery system isconfigured to have a mobile framework with a support surface capable ofsupporting a turntable. A plurality of spools can be placed upon theturntable or the support surface, with each spool configured to supporta coil of rebar material. A coil leveler is also movably supported uponthe turntable at a location adjacent one of the plurality of spools andconfigured to receive rebar material from the coil so as to performstraightening of the rebar material. The turntable is rotatable so thatthe coil leveler can be positioned so that its output is positioned at atransport orientation and a plurality of delivery orientations.

In some aspects, the mobile re-bar delivery system is configured so thatthe mobile framework is part of a flatbed trailer. In other aspects, themobile re-bar delivery system wherein the mobile framework is part of aflatbed truck.

In certain aspects, the mobile re-bar delivery system further includes abending tool mounted to the support surface. Further, the mobile re-bardelivery system may also include welding, heating and cutting tools,each of which are mountable to the vehicle support surface, turntable ormobile framework.

In other aspects, the mobile re-bar delivery system is supported by amobile framework which has a support platform which is movable by aloader, and which can be carried by a trailer or a flatbed truck fortransport to a construction site. The support platform may be modularand separable, thereby allowing for the loading and unloading ofindividual modular components, which can then be combined at a job site.

BRIEF DESCRIPTION OF THE DRAWINGS

Further advantages of the re-bar delivery system will be betterunderstood from the detailed description set forth below along with thedrawings, in which:

FIG. 1 is a perspective view of one embodiment of the re-bar deliverysystem;

FIG. 2 is a schematic top view of an another embodiment of the re-bardelivery system;

FIG. 3 shows an alternative layout for the re-bar delivery system;

FIG. 4 illustrates one type of coil spool that could be used with themobile delivery system;

FIG. 5 shows the manner in which stock re-bar coils are typicallydelivered from a supplier or foundry;

FIG. 6 presents an alternative embodiment of the re-bar delivery systemwith a turntable mechanism included;

FIG. 7 shows another view of the alternative re-bar delivery systemillustrated in FIG. 6 with the turntable mechanism in a side deliveryposition;

FIG. 8 is a top view of the alternative re-bar delivery system shown inFIG. 6 with the turntable mechanism in a transport position;

FIG. 9 is a second top view of the alternative re-bar delivery system ofFIG. 6 with turntable mechanism in a first side delivery position;

FIG. 10 shows another top view of the re-bar delivery system shown inFIG. 6 with the turntable mechanism in a second side delivery position;and

FIG. 11 illustrates an alternative embodiment where the mobile re-bardelivery system is a modular unit which can be transported to and placedat a jobsite.

DESCRIPTION

Outlined below are various embodiments of a mobile re-bar deliverysystem which is capable of delivering re-bar to a jobsite of nearlyunlimited length. Additionally, the mobile re-bar delivery system can beconfigured to produce straight re-bar stock, to cut re-bar to a desiredlength, and to carry out bending operations, thereby allowing forcustomization of rebar structures while at the jobsite.

The components used to deliver and customize re-bar are carried by amovable platform or vehicle to allow for mobility. In some embodiments,these components are carried by complementary vehicles such as a traileror related vehicle. For example, coiled rebar could be carried by afirst vehicle and the outfeed systems (or coil levelers), a cuttingdevice and bending tools could be carried by a second vehicle.Alternatively, all of these components can be carried by a singlevehicle. As will be discussed in further detail below, it iscontemplated that several of these systems could be modular and easilyreplaceable depending on the particular needs of the constructionproject.

FIGS. 1 & 2 show one embodiment of the re-bar delivery system 10 whereall components are carried upon a trailer 42. As shown, the re-bardelivery system 10 includes a set of coil supports 20 at a firstlocation on the vehicle/trailer 42. Here, a pair spools 24 and 25 areconfigured to rotatably support coils 22 of re-bar stock (not shown). Asis well known, re-bar stock is often supplied in a coil, as is generallyillustrated in FIG. 5 . Although many variations are possible, one typeof spool 24 designed to support and handle a coil of re-bar isillustrated in FIG. 4 . Those skilled in the art will recognize thatFIG. 4 shows three spools—a first spool 26, a second spool 27 and athird spool 28—each of which are all supported on a framework 30. Thisconfiguration creates further advantages which are discussed in furtherdetail below.

In the embodiment schematically shown in FIG. 2 , re-bar delivery system10 is again configured to be carried on a trailer 42 which is pulled bya truck 44 of some type. It is contemplated that re-bar delivery system10 could also be carried upon a flat-bed truck, a semi-trailer, or othertypes of vehicles. Each of these options allow easy transportation to ajobsite. In this embodiment, a pair of spools 24 and 25 are supportedupon a rear portion of trailer 42. As discussed in further detail below,the embodiment shown in FIG. 2 accommodates delivery of re-bar supply ata front portion of trailer 42.

Referring again to FIGS. 1 & 2 , the re-bar delivery system 10 furtherincludes a straightening and feeding system, or coil leveler, 50 whichis adjacent the spools 24 and 25. As is well known, most wire or coiledmetal will have curvature, twist or memory when pulled from a supplycoil. Coil leveler 50 will remove this curvature, twist or memory in there-bar material. Coil leveler 50 can take many forms but is designed topull re-bar material from a respective coil 22. At an output 58 of coilleveler 50, re-bar is supplied in a generally linear configuration,which can then be used as needed for use in the particular constructionproject. In this embodiment, it is contemplated that coil leveler 50 canbe rotatably mounted to a top surface 44 of trailer 42, thus allowingfor delivery of re-bar material to either side of trailer 42. In FIG. 2, the alignment to a first side is shown in solid lines, while alignmentto a second side is shown in dashed lines. Alternatively, coil leveler50 can be slidably mounted to trailer 42 to further accommodatepositioning and alignment of components, thus providing additionaldelivery flexibility to users. As shown, in the embodiment of FIG. 2 ,output 58 of coil leveler 50 is positioned near the front of trailer 42.In many situations this may be convenient while at a jobsite sincepositioning of trailer 42 may be challenging. Having output 58configured in this manner allows users to park trailer 42 at a curb oron a roadside, while also providing delivery of re-bar material to aconvenient location.

In an alternative embodiment, shown in FIG. 3 , re-bar delivery system10 will also include a cutter 60 positioned adjacent output 58 ofleveler 50. Cutter 60 can be moved along a mounting track 62, to allowfor desired positioning. Coil leveler 50 is again rotatably mounted totrailer surface 44, thus allowing its output 58 to be aligned in manydifferent ways. By allowing cutter 60 to move along track 62, multiplesupply operations can be achieved. As will be appreciated, cutter 60 canbe used to cut re-bar once a desired length has been fed from output 58.Although not specifically illustrated in FIG. 3 , cutter 60 could alsobe rotatable along track 62 to provide further flexibility to users.

In the alternative embodiment shown in FIG. 3 , a bending system 70 isalso carried by trailer 42, which provides mechanisms necessary toperform bending operations. Bending system 70 could be removable, and/orcould include a number of bending modules that are capable of beingselectively mounted on trailer 42. Should the user know that certainbeing operations will be repeatably needed while at the jobsite, acustomized bending module 72 could be included to provide additionalefficiency. In the system generally illustrated in FIG. 3 , cutter 60could also be rotatable and slidable along the surface of the trailer42, again thereby allowing for cutting operations to be carried out inline with coil leveler 50. It is also contemplated that bending system70 would be rotatable, thereby allowing it to be aligned with cutter 60,and thus providing convenient access and positioning to users.

Although not specially illustrated in FIGS. 1-3 , delivery system 10will also include a power supply necessary to drive leveler 50 and theoperation of other components. This could be an on-board generator, withvarious components being electrically powered or a hydraulic system towork with hydraulically powered tools. Alternatively, leveler 50 couldbe self-powered, or power could be provided by a related truck orvehicle. As will be appreciated, many alternatives are available.

As an additional way to provide re-bar suppliers with flexibility andenhanced capabilities an alternative re-bar delivery module 100 could beconfigure as a customized re-bar delivery module that could betransported to a job site and placed in a beneficial location. Oneexample of this embodiment is illustrated in FIG. 11 , wherein thecustomized re-bar delivery module 100 would include a framework 110 thatincludes end members 102, side members 104 and a number of cross members108. As illustrated, this creates a self-contained unit which supportsmany of the above-mentioned components (e.g., a coil support platform120, a coil leveler 150 and a cutter 160). Coil support platform 120 isconfigured to support a first spool 124 and a second spool 125 at alocation adjacent to coil leveler 150. As illustrated, cutter 160 issituated on a tool platform 162 which has a number of tool mount slots164. In this embodiment, any number of additional tools (i.e. welders,benders, etc.) could be easily mounted on tool platform 162 by havingmounting pegs or related structures that are inserted into tool mountslots 164.

It is then contemplated that the re-bar delivery module 160 could beplace upon a delivery truck or delivery trailer and transported to a jobsite as needed. Re-bar delivery module 100 would then be left at thejobsite until all re-bar work is completed. In this way, a trailer ortruck is not “dedicated” to the custom re-bar delivery system. Toaccommodate transport, appropriate slots 108 are formed in sidewalls 104to allow forks (e.g. the forks of a fork-lift, front end loader or boomtruck) to be inserted into these slots and allow the entire module 100transported and positioned as necessary.

In addition, the use of a modular approach (e.g. using rebar deliverymodule 100) may allow for additional flexibility by having certainportions of the module be expandable. As one example, first coil support124 and second coil support 125 could be placed up a hinged or movableportion of the framework 110 without the need for platform 120. Thiswould then allow for the use of expanded space on rebar delivery module100) when in use. Alternatively, this could allow for the ability tohandle multiple spools. Also, as mentioned, it would be possible to addbending, welding, or tying tools to the framework as needed. Also, theoverall module could be formed of parts or segments that are combined atthe job site, thus avoiding possible issues related to transportation.

While several advantages and beneficial features of the re-bar deliverysystem are apparent from the discussion above, some specificcharacteristics provide unique capabilities. For example, re-bardelivery system 10 is very mobile, thus providing the ability to bringcustom re-bar delivery to the jobsite. Further, the system has theability to produce re-bar of virtually any length (limited only by theoverall length of rebar that can be carried upon a spool). The mobilesystem is easily reconfigurable, providing many tools for furthercustomization of rebar segments. Additionally, the system can handle andconfigure re-bar of different thicknesses and types without the need foradjustment or using alternative delivery mechanisms.

Referring now to FIG. 6 , an alternative re-bar delivery system 80 isgenerally illustrated. Again, alternative re-bar delivery system 80 isconfigured to be carried by a trailer 81, having a trailer bed 82,wheels 84, and a connection or pulling mechanism (i.e., a hitchmechanism 86). Alternative re-bar delivery system 80 could be configuredin many different ways, such as a system carried on a flatbed truck, ora standalone platform that is easily removable utilizing a frontendloader or forklift of some type. As further illustrated in FIG. 6 ,alternative re-bar delivery system 80 provides a number of mechanisms tosupport a first coil 96, a second coil 97 and a third coil 98. Generallyspeaking, the supporting mechanisms (not shown) are similar to thespools discussed above, and more fully shown in FIG. 4 . In thisparticular embodiment, trailer bed 82 also supports a turntable 90 whichis specifically configured to be movable, thus providing a number ofdelivery options. Here, turntable 90 includes a spool mechanism tosupport first coil 96, and also has a straightening and feeding system94 (i.e., a coil leveler 94). In this configuration, straightening andfeeding system 94 is capable of receiving re-bar material from coil 96,and performing the necessary steps to straighten and feed re-barmaterial to an output 92. Again, this operation may require removingmemory and/or twists that had been incorporated during the manufacturingoperations so that re-bar material is provided in a straight andcontinuous manner. In the configuration shown in FIG. 6 , output 92 ofstraightening and feeding mechanism 94 is directed towards a corner ofthe trailer bed. This allows material to be fed to that location, ifdesired by contractors.

Turning to FIG. 7 , alternative re-bar delivery system 80 is illustratedwith turntable 90 rotated to a side delivery position. As can be seen,output 92 of straightening and feeding system 94 is now directed to aside portion of trailer bed 82, thus changing the delivery location. AsFIGS. 6 and 7 generally illustrate, turntable 90 allows the deliverylocation to be modified.

Referring now to FIGS. 8-10 , a top view of alternative re-bar deliverysystem 80 is shown. In FIG. 8 , turntable 90 is positioned in atransport position, where all parts are contained above trailer bed 82,so that nothing extends outwardly or causes interference whiletransporting alternative delivery system 80 to the jobsite. Turning nowto FIG. 9 , turntable 90 has been rotated to one side of trailer bed 82,to provide delivery to an alternative location. In a related manner,FIG. 10 illustrates turntable 90 rotated to an opposite side of trailerbed 82, thus accommodating a different delivery location. As will beappreciated, turntable 90 can be appropriately rotated to many differentlocations to achieve desired alignment as necessary.

Also illustrated on FIGS. 6-10 is a bending mechanism 88 positioned atone corner of the trailer bed. This allows further manipulation andconfiguration of re-bar as needed. As generally discussed above,additional tools could be carried by a trailer bed, such as cutters,benders, and welding machines. Further, these additional tools may beeasily movable or mountable at different locations on the trailer 80.

Although not specifically illustrated above, it is contemplated that thevarious components could be modular to enhance flexibility. For example,each spool 22 could be mounted on base 30, such as that illustrated inFIG. 4 . In this case, base 30 is configured to be easily handled/movedby a forklift or front-end loader. Using this approach, once a coil 22is loaded on spool 24 (away from trailer 42), the coil 22 and spool 24could collectively be moved to trailer 42 by simply handling base 30.Using this approach, base 30 and upper surface 44 of trailer 42 couldhave interlocking structures that allow for selective mounting andremoval. In a similar manner a spool assembly could be used, wheremultiple spools are carried by a base and the base can be mounted andremoved from the surface 44 of trailer 42.

Those skilled in the art may consider the above system as beingparticularly adapted to the delivery of custom lengths of steel or metalre-bar material. That said, the same system could also accommodatefiberglass or composite re-bar materials. When configured to accommodatefiberglass or composite re-bar materials, the configuration of thecutters and levelers will be configured to accommodate the uniquecharacteristics of these materials.

Various embodiments of the invention have been described above forpurposes of illustrating the details thereof and to enable one ofordinary skill in the art to make and use the invention. The details andfeatures of the disclosed embodiment[s] are not intended to be limiting,as many variations and modifications will be readily apparent to thoseof skill in the art. Accordingly, the scope of the present disclosure isintended to be interpreted broadly and to include all variations andmodifications coming within the scope and spirit of the appended claimsand their legal equivalents.

1. A mobile system for providing supply of reinforcing bar materials toa jobsite, comprising: a vehicle having a support frame and a supportsurface; a coil handler supported by the support surface, the coilhandler configured to rotatably support a coil of reinforcing barmaterial in a manner which allows the reinforcing bar materials to beunwound and fed from the coil; a mobile outfeed device positionedadjacent to the coil handler, the mobile outfeed device configured toreceive the reinforcing bar materials and to perform a straighteningoperation which will provide a straightened rebar material at an outputof the mobile outfeed device; and a mobile cutter positioned adjacentoutfeed device to cut reinforcing bar materials to a desired length whenthat length has been provided through the output.
 2. The mobile systemof claim 1 wherein the outfeed device and the mobile cutter arerotatably supported upon the vehicle support surface to provide forselective alignment.
 3. The mobile system of claim 1 further comprisinga bending device positioned adjacent the cutter and configured to bendthe desired length of reinforcing bar materials into a predeterminedconfiguration.
 4. The mobile system of claim 3 wherein the outfeeddevice, the mobile cutter and the bending device are rotatably supportedupon a turntable which is positioned upon the vehicle support surface.5. A mobile rebar delivery system, comprising: a mobile framework havinga support surface; a turntable supported by the support surface; aplurality of spools configured to support a coil of rebar material,wherein at least one of the plurality of spools is supported on theturntable; and a coil leveler movably supported upon the turntable, thecoil leveler having an input positioned adjacent the at least one of theplurality of spools configured to receive rebar material from the coil,the coil leveler further configured to perform a straightening processand provide straightened rebar material at a leveler output; wherein theturntable is rotatable so that the coil leveler output is positionableat a transport orientation and a plurality of delivery orientations. 6.The mobile rebar delivery system of claim 5 wherein the turntablesupports two spools.
 7. The mobile rebar delivery system of claim 5wherein the mobile framework is part of a flatbed trailer.
 8. The mobilerebar delivery system of claim 5 wherein the mobile framework is part ofa flatbed truck.
 9. The mobile rebar delivery system of claim 5 furthercomprising a bending tool mounted to the support surface.
 10. The mobilerebar delivery system of claim 5 wherein the mobile framework compriseda support platform movable by a loader which can be placed upon atrailer or a flatbed truck for transport to a jobsite.
 11. The mobilerebar delivery system of claim 5 wherein the plurality of spools are allsupported on the turntable.